Edge-Wrapped Panel and Methods for Edge-Wrapping a Panel

ABSTRACT

An edge-wrapped panel and methods for edge-wrapping a panel. The panel comprises a substrate layer, a laminate layer, and at least one retainer. The laminate wraps around the substrate first edge and around the retainer first edge and sandwiches the substrate and the retainer between a first portion of the laminate and a second portion of the laminate. A method for edge-wrapping the panel includes the steps of securing the retainer to the laminate and then snap-wrapping the laminate flap around the edge of the panel. A stiffness and curvature in the retainer facilitates the swift snap-wrap movement.

BACKGROUND

1. Technical Field

The present disclosure relates to an edge-wrapped panel, such as anaircraft interior panel, and to methods for edge-wrapping a panel with alaminate.

2. Description of Related Art

Many aircraft interior panels are constructed of rigid or semi-rigidsubstrate that is covered on at least one side with a laminate. Thelaminate is typically decorative, and provides the panel with a pleasingoutward appearance. The substrate may comprise a multilayer composite.For example, one type of substrate includes first and second outerlayers of a fibrous material such as fiberglass or carbon. The outerlayers may sandwich an inner layer of honeycomb core. The laminate isapplied over one of the outer layers so that the panel provides apleasing outward appearance when it is installed inside an aircraft.

One type of laminate that is commonly used today is TEDLAR®, a film orsheet made from polymers of vinyl fluoride. The laminate is molded andbonded to the substrate using a vacuum forming process. During vacuum,forming, excess laminate is left around the edges of the panel. Theexcess is wrapped around the substrate and bonded to the back surfacethereof to provide clean edges.

Edge-wrapping is commonly performed by hand using heat guns andchemicals. Workers apply glue to the back surface of the substrate, thenstretch and pull the laminate around the substrate edges and secure itto the back surface. The laminate material is flexible. Therefore, theworker must pull the excess around its respective edge in stages,pulling only as much as he or she can with two hands. He or she maystart at the center of one edge and work toward the ends, or start at afirst end of that edge and work toward the opposite end of that edge.When the worker has pulled all portions of the excess laminate aroundthe edge and secured it to the back surface of the substrate, he or shesecures a retainer, which is typically a plastic strip, over thelaminate on the panel back surface. The retainers may include featuresthat facilitate attachment of the panel within the aircraft interior.

The hand edge-wrapping process is difficult to master, takes a long timeto complete, and presents serious ergonomic issues. The stretching andpulling of the laminate, and the pressing of the laminate against thesubstrate back surface can cause repetitive stress injuries to hands,wrists and arms. Workers also must wear heavy gloves to insulatethemselves from the heat guns and the hot laminate. Some workers alsowear respirators to protect from solvent fumes.

SUMMARY

The preferred embodiments of the present edge-wrapped panel and methodsfor edge-wrapping a panel have several features, no single one of whichis solely responsible for their desirable attributes. Without limitingthe scope of this panel and these methods as expressed by the claimsthat follow, their more prominent features will now be discussedbriefly. After considering this discussion, and particularly afterreading the section entitled “Detailed Description of the PreferredEmbodiments”, one will understand how the features of the preferredembodiments provide advantages, which include quick and easyedge-wrapping of panels with attendant reductions in repetitive stressinjuries and dangers from exposure to heat and chemicals.

One aspect of the present panel and methods includes the realizationthat current methods of edge-wrapping panels are slow and tedious, andtherefore labor intensive and expensive. Further, these methods presentserious dangers to those workers who must pull and stretch the laminatesaround the panel substrates. Accordingly, an improved panel and improvedmethods for edge-wrapping the panel would lower the cost of producingpanels and increase the safety of workers.

In accordance with the above realizations, one embodiment of the presentedge-wrapped panel and methods for edge-wrapping a panel comprises amethod for edge-wrapping a panel with a laminate. The method comprisesthe step of providing a substrate having a first edge and a backsurface. The method further comprises the step of positioning at leastone retainer spaced from the first edge of the substrate, the at leastone retainer having a back surface. The method further comprises thesteps of positioning the laminate over the substrate and the at leastone retainer, securing the laminate to the substrate and to the at leastone retainer. The method further comprises the steps of wrapping thelaminate around the first edge of the substrate to thereby bring the atleast one retainer back surface into facing arrangement with thesubstrate back surface, and securing the at least one retainer backsurface to the substrate back surface.

Another embodiment of the present edge-wrapped panel and methods foredge-wrapping a panel comprises a panel for an aircraft interior. Thepanel comprises a substrate layer having at least a first edge, alaminate layer, and at least one retainer having at least a first edgeextending substantially parallel to the substrate first edge. Thelaminate wraps around the substrate first edge and around the retainerfirst edge and sandwiches the substrate and the retainer between a firstportion of the laminate and a second portion of the laminate.

BRIEF DESCRIPTION OF THE DRAWINGS

The preferred embodiments of the present edge-wrapped panel and methodsfor edge-wrapping a panel will now be discussed in detail with anemphasis on highlighting the advantageous features. These embodimentsdepict the novel and non-obvious panel and methods shown in theaccompanying drawings, which are for illustrative purposes only. Thesedrawings include the following figures, in which like numerals indicatelike parts:

FIG. 1 is a flowchart illustrating steps in an integrated aircraftproduction process;

FIG. 2 is a front elevation view of an aircraft interior panelconstructed in accordance with one embodiment of the present methods foredge-wrapping a panel;

FIG. 3 is a right-side elevation view of the aircraft interior panel ofFIG. 2;

FIG. 4 is a flowchart illustrating steps in one embodiment of thepresent methods for edge-wrapping a panel;

FIG. 5 is a schematic bottom view of a panel during one step of themethod of FIG. 4;

FIG. 6 is a schematic bottom view of the panel of FIG. 5 during anotherstep of the method of FIG. 4;

FIG. 7 is a schematic bottom view of the panel of FIG. 5 during anotherstep of the method of FIG. 4; and

FIG. 8 is a schematic bottom view of the panel of FIG. 5 during anotherstep of the method of FIG. 4.

DETAILED DESCRIPTION

FIG. 1 illustrates an integrated aircraft production process 100, inaccordance with embodiments of the present disclosure. As used herein,the integrated aircraft production process 100 also may includemanufacturing, support, or both. Typically, the process 100 includes apre-production phase S102, a production phase S104, and apost-production phase S106. The pre-production phase S102 may includeaircraft design S110, including design of subassemblies and components,and material specification and procurement S120. Material specificationand procurement S120 may include selection and procurement of componentsfabricated, or subassemblies manufactured, by third parties. Examples ofsuch third parties include, without limitation, vendors, subcontractors,and suppliers. The production phase S104 may include componentfabrication and/or subassembly manufacturing S130, and aircraft assemblyS140. The pre-production phase S102 and production phase S104 can beelements of an integrated manufacturing process S105, including one ormore of aircraft and component design, development, and simulationprocesses; material, component, and sub-assembly specification andprocurement processes; automated production planning processes;fabrication and assembly processes; and quality control processes.

Frequently, aspects of a modern aircraft production process, such as theintegrated process 100, do not end with final assembly, but may extendover the service life of an aircraft. These aspects may involveiterative and interactive collaborations between manufacturer,governmental authorities, customers and aircraft operators. Accordingly,the integrated production process 100 can include a post-productionphase S106. The post-production phase S106 may include aircraft deliveryand qualification S150, and/or aircraft maintenance and service S160.The aircraft delivery and qualification S150 may include providing anaircraft to customer specifications, which may have changed from thetime the aircraft was assembled. Thus, delivery and qualification caninclude repair, modification, and/or revision of one or more elements ofthe aircraft after delivery to a customer or operator. Also, it may bedesirable to perform a modification, maintenance, a repair, and/or anupgrade to an aircraft in the service interval between aircraft deliveryand retirement. Therefore, aircraft maintenance and service S160 caninclude repair, maintenance, modification, and/or upgrade of a portionof an airframe, including an airframe manufactured or assembled usingtraditional, pre-existing materials, components, and/or subassemblies.

FIGS. 2 and 3 illustrate an aircraft interior panel 10 constructed inaccordance with one embodiment of the present methods for edge-wrappinga panel 10. With reference to FIG. 2, the panel 10 is generallyrectangular in front elevation view, but includes a curvature about afirst axis x that runs lengthwise along the panel, as shown in FIG. 3.The front surface 12 of the panel 10 curves inwardly from a top edge 14to a bottom edge 16, while the rear surface 18 of the panel 10 curvesoutwardly. The panel 10 is adapted to be installed on the interior of anaircraft (not shown) to provide a decorative covering for the fuselageand any cables, wires, pipes, etc. extending along the fuselage. Thepanel 10 also includes two window openings 20 (FIG. 2). Those ofordinary skill in the art will appreciate that the panel 10 could haveany of a variety of different configurations, and could be virtually anysize.

FIG. 2 illustrates the panel 10 at an intermediate stage ofedge-wrapping. A laminate 22 has been applied to the front surface 12 ofthe panel 10. The laminate may be TEDLAR® or any other suitablematerial. At a left edge 24 of the panel 10 excess laminate 22 has beenedge-wrapped around the panel 10, leaving a clean edge with a pleasingappearance. At a right edge 26 of the panel 10 a flap 28 of excesslaminate 22 remains. This flap 28 will be edge-wrapped around the panel10 in accordance with one embodiment of the present methods, which aredescribed in detail below.

FIG. 4 illustrates steps in one embodiment of the present methods foredge-wrapping a panel. FIGS. 5-8 are schematic views of the panelcomponents used in the method of FIG. 4 as viewed from a top edge-onperspective with a front surface of the panel facing upward. Forclarity, the curvature in the panel 10 has been omitted from FIGS. 5-8.However, the curvature in the panel 10, which is clearly visible in FIG.3, contributes to the advantageous features of the present methods foredge-wrapping a panel, as described in detail below.

With reference to FIG. 4, in one embodiment of the present methods asubstrate is provided, as shown at step S400. In step S402 at least oneretainer is positioned adjacent the substrate and spaced from a firstedge of the substrate. In certain embodiments opposite edges of thepanel are edge-wrapped, and therefore in step S404 two retainers may bepositioned spaced from opposite edges of the panel. In step S404 alaminate is positioned over the substrate and the retainer(s), and instep S406 the laminate is secured to the substrate and the retainer(s).In step S408 the laminate is wrapped around the first edge of thesubstrate to bring the back surface of the retainer(s) into facingarrangement with the substrate back surface. In step S410 the backsurface of the retainer(s) is secured to the substrate back surface.

FIGS. 5 and 6 further illustrate the steps S400-S410 with reference toschematic representations of the components of the panel, including asubstrate 30, first and second retainers 32, 34 and a laminate 22. InFIG. 5 the components are arranged on a work surface 36, which maycomprise a vacuum table, for example. However, those of ordinary skillin the art will appreciate that no work surface need be provided. InFIG. 5, spacing between adjacent components has been exaggerated forclarity. In practice the components may contact one another.

In one embodiment the substrate 30 comprises a multilayer compositeincluding first and second outer layers 38 and at least one inner layer40 (FIG. 5). For example, and without limitation, the outer layers 38may comprise a fibrous material, such as fiberglass, carbon or KEVLAR®,and the inner layer 40 may comprise a material having internal cavities,such as honeycomb core. Those of ordinary skill in the art willappreciate that the substrate 30 could comprise alternative materials,and that the substrate 30 need not comprise multiple layers.

As illustrated in FIG. 5 a first spacer 42 is positioned adjacent afirst edge 44 of the substrate 30 and a second spacer 46 is positionedadjacent a second edge 48 of the substrate 30 opposite the first edge44. The first retainer 32 is positioned adjacent the first spacer 42such that the spacer 42 is between the first retainer 32 and thesubstrate first edge 44. The second retainer 34 is positioned adjacentthe second spacer 46 such that the spacer 46 is between the secondretainer 34 and the substrate second edge 48. The laminate 22 extendsover the substrate 30, spacers 42, 46 and retainers 32, 34 withoverhanging portions 50 extending past each retainer 32, 34. Again, inFIG. 5 spacing between adjacent components has been exaggerated forclarity. In actual practice some or all of the components may be incontact with one another. Those of ordinary skill in the art willappreciate that the spacers 42, 46 need not be used in the presentmethods. The spacers 42, 46, however, help to ensure that the spacingbetween the substrate 30 and the retainers 32, 34 remains consistent asthe method of fabricating the panel 10 is repeated.

As shown in FIG. 5, each of the retainers 32. 34 and spacers 42, 46 hasa substantially rectangular cross-section. However, those of ordinaryskill in the art will appreciate that these components could havecross-sections of virtually any shape. Further, relative dimensions ofeach component in the figures should not be interpreted as limiting. Inone embodiment the retainers 32, 34 comprise elongate, relatively thinstrips of a rigid or semi-rigid material, such as a polymer. In oneembodiment the retainers 32, 34 are constructed of ULTEM®. The retainers32, 34 provide additional stiffness to the portions of the laminate 22that overhang the panel 10. The additional stiffness advantageouslyfacilitates quick and easy edge-wrapping of the panel 10, as explainedin detail below.

The spacers 42, 46 may be somewhat thicker than the retainers 32, 34,but also generally comprise elongate strips or bars of a rigid orsemi-rigid material. For example, the spacers 42, 46 could beconstructed of a metal or a polymer. In one embodiment a width of eachspacer 42, 46 is at least equal to a sum of the thicknesses of thesubstrate 30 and one of the retainers 32, 34. Each spacer 42, 46 thusensures that sufficient laminate 22 material is reserved for wrappingaround each edge 44, 48 of the substrate 30 and the adjacent retainer32, 34, as described in detail below.

In one embodiment of the present methods for edge-wrapping a panel thecomponents illustrated in FIG. 5 are arranged on the work surface 36 asshown, but in no particular order. For example, the substrate 30 may beplaced on the work surface 36 prior to the spacers 42, 46, or viceversa. After the laminate 22 is placed over the components it is securedto the substrate 30 and the retainers 32, 34. Alternatively, thelaminate 22 may be secured to the substrate 30 prior to placing thesubstrate 30 and the laminate 22 on the work surface 36. The laminate 22may be secured to the substrate 30 and the retainers 32, 34 usingadhesive, heat sealing, ultrasonic or megasonic welding, or othersecurement techniques.

The laminate 22 is not secured to the spacers 42, 46, at least notpermanently. If the spacers 42, 46 are left on the work surface 36during the securing step, the laminate 22 may be temporarily secured tothe spacers 42, 46. However, the spacers 42, 46 are subsequentlydetached from the laminate 22 in the event that any adherence occurs. Inone embodiment the spacers 42, 46 are constructed of a material thatdoes not bond to the laminate 22 material so that no adherence occurs.Alternatively, the spacers 42, 46 may be removed from the work surface36 before the laminate 22 is secured to the substrate 30 and to theretainers 32, 34.

FIG. 6 illustrates the panel 10 as it appears in an intermediate step ofone embodiment of the present methods, after the laminate 22 has beensecured to the substrate 30 and to the retainers 32, 34 and after thespacers 42, 46 have been removed. Again, in these figures spacingappears between the laminate 22 and the substrate 30, and between thelaminate 22 and the retainers, even though the laminate 22 is secured tothese components. In FIGS. 6-8 the work surface 36 has been omitted forclarity. Those of ordinary skill in the art will appreciate that allsteps in the embodiments of the present methods may be carried out on awork surface or without a work surface.

With reference to FIG. 6, the retainers 32, 34 are secured to respectiveflaps 28 of the laminate 22 that overhang the edges 44, 48 of thesubstrate 30. An adhesive layer (not shown) may be applied to a backsurface 52 of the retainers 32, 34. Alternatively, or in addition, anadhesive layer (not shown) may be applied to a back surface 54 of thesubstrate 30 near the first and second edges 44, 48. The adhesive maybe, for example, double-sided tape, glue or any other adhesive. Theadhesive may further be applied to the retainers 32, 34 and/or to thesubstrate 30 prior to the step of assembling the panel 10 components(FIG. 5). It is advantageous, however, if the adhesive does not causethe retainers 32, 34 and/or the substrate 30 to stick to the worksurface 36. In one embodiment the back surface 52 of each retainer 32,34 includes a strip of double-sided tape with a backing (not shown).After the laminate 22 is secured to the substrate 30 and the retainers32, 34 the backing is removed from the double-sided tape to expose theadhesive surface.

With reference to FIGS. 7 and 8, any excess laminate 22 may be trimmedfrom the edges 44, 48 of the retainers, and the laminate 22 is thenfolded around the edges 44, 48 of the substrate 30. During the foldingsteps each flap 28 “snaps” around its respective edge 44, 48 in onerapid motion so that the retainer back surface 52 quickly comes intofacing contact with the substrate back surface 54. The “snap-wrap”effect results from the stiffness and curvature (FIG. 3) of the flaps28. As described earlier, the retainers 32, 34 impart stiffness to theflaps 28 overhanging the edges 44, 48 of the substrate 30. In addition,the retainers 32, 34 and flaps 28 extend along side edges 44, 48 of thesubstrate 30, which arch about the first lengthwise axis from the topedge 14 of the panel 10 to the bottom edge 16 thereof (FIG. 3). Thecurvature of the retainers 32, 34 about the lengthwise axis impartsadditional stiffness so that the retainers 32, 34 are more resistant tobending around the side edges 44, 48 of the substrate 30. Thus, as eachflap 28 is bent it initially offers strong resistance to being foldedabout its respective edge 44, 48. The resistance increases as the flap28 is bent further until a threshold is reached. At the threshold theforces acting on the flap 28 are in equilibrium, but as further bendingforce is applied the forces tending to prevent the flap 28 from furtherbending quickly dissipate and the flap 28 snaps around its respectiveedge 44, 48. The snapping effect quickly brings the retainer backsurface 52 into facing contact with the substrate back surface 54.

In some embodiments, adhesive is applied to the retainers 32, 34 and/orthe substrate 30 back surface prior to snapping the flaps 28 around theedges 44. 48. Thus, when the retainer back surface 52 snaps into contactwith the substrate back surface 54, the adhesive bonds the retainers 32,34 and the substrate 30 to one another, thereby quickly completing theedge-wrapping procedure. The adhesive may be double-sided tape, forexample, and an operator may perform a step of removing a backing fromthe tape prior to snapping the retainers 32, 34 around the substrate 30.

Those of ordinary skill in the art will appreciate that the retainers32, 34 may be secured to the substrate 30 using other techniques, suchas heat sealing, ultrasonic or megasonic welding, etc. When using suchsecuring techniques, adhesive might not be applied to the retainers 32,34 and/or the substrate 30. Thus, when the retainers 32, 34 are snappedaround the substrate edges 44, 48 the components will not instantly bondto one another. Nevertheless, the snapping action of the retainers 32,34 and flaps 28 quickly brings the retainers 32. 34 into facing contactwith the substrate back surface 54, and the stiffness and curvature ofthe flaps 28 holds the retainers 32, 34 against the substrate 30,facilitating the process of securing the retainers 32, 34 to thesubstrate back surface 54.

The steps of folding the flaps 28 about the edges 44, 48 may beperformed by hand. For example, an operator may flip the panel 10 overon the work surface 36 so that its rear surface 18 faces upward.Alternatively, the operator may stand the panel 10 up with its top edge14 or bottom edge 16 resting on the floor. He or she may then grasp thetop edge 14 or bottom edge 16 with one hand and fold each of the flaps28 over their respective edges 44, 48 with his or her opposite hand.

The present method advantageously eliminates the need to perform thetedious prior art edge-wrapping process described above. In that methodthe operator must pull the laminate flaps by hand, step-by-step, andstretch them around the substrate edges to secure them to the backsurface of the substrate. The process is slow and tedious, and can causerepetitive stress injuries. It also presents other dangers to theworkers, such as those from heat guns and chemical solvents. The presentsnap-wrap eliminates the tedious pulling and stretching. The time thatit takes to complete a panel is thus reduced, which in turn reduces thecost. The present methods increase repeatability and decrease rework.Further, in embodiments where adhesive tape is used to secure theretainers to the substrate, the dangers from heat guns and chemicalsolvents are also eliminated.

With reference to FIG. 8, the laminate 22 wraps around the substrateedges 44, 48 and around the retainers 32, 34, sandwiching the substrate30 and the retainers between first portions 56 of the laminate 22 and asecond portion 58 of the laminate 22. A spacing between the substrate 30and each retainer 32, 34 during the step shown in FIG. 5 determines thelocation of the retainer on the substrate back surface 54. For example,if the spacing between the substrate 30 and the retainer 32, 34 isexactly equal to the sum of the thicknesses of the substrate 30 and theretainer 32, 34, then the substrate edges 44, 48 and the retainers 32,34 will be flush with one another as shown in FIG. 8. If however, thespacing between the substrate 30 and the retainers 32, 34 is greaterthan the sum of the thicknesses, then the substrate 30 will overhang theretainers 32, 34.

The above description presents the best mode contemplated for carryingout the present edge-wrapped panel and methods for edge-wrapping apanel, and of the manner and process of making the panel and practicingthe methods, in such full, clear, concise, and exact terms as to enableany person skilled in the art to which it pertains to make and use thispanel and to practice these methods. This panel and these methods are,however, susceptible to modifications and alternate constructions fromthat discussed above that are fully equivalent. Consequently, this paneland these methods are not limited to the particular embodimentsdisclosed. On the contrary, this panel and these methods cover allmodifications and alternate constructions coming within the spirit andscope of the panel and methods as generally expressed by the followingclaims, which particularly point out and distinctly claim the subjectmatter of the panel and methods.

1-17. (canceled)
 18. A panel for an aircraft interior, the panelcomprising: a substrate layer having at least a first edge; a laminatelayer; and at least one retainer having at least a first edge extendingsubstantially parallel to the substrate first edge; wherein the laminatewraps around the substrate first edge and around the retainer first edgeand sandwiches the substrate and the retainer between a first portion ofthe laminate and a second portion of the laminate.
 19. The panel ofclaim 18, wherein the substrate comprises a plurality of layers.
 20. Thepanel of claim 19, wherein the substrate comprises a first outer layer,a second outer layer and at least a first inner layer.
 21. The panel ofclaim 20, wherein the outer layers comprise a fibrous material and theinner layer comprises honeycomb paper.
 22. The panel of claim 18,wherein the retainer comprises an elongate, thin strip of a rigid orsemi-rigid material.
 23. The panel of claim 22, wherein the retainer isconstructed of a polymer.